WA-I-O_100161778_2000019063_Rev X Installation & Operation Manual Models: 125 - 200 ⚠ WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. -- This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present. -- WHAT TO DO IF YOU SMELL GAS •Do not try to light any appliance. •Do not touch any electric switch; do not use any phone in your building.
Contents HAZARD DEFINITIONS .................................................. 2 PLEASE READ BEFORE PROCEEDING ..................... 3 THE ARMOR WALL MOUNT WATER HEATER -- HOW IT WORKS .......................................................................... 4-5 RATINGS .......................................................................... 6 1. DETERMINE WATER HEATER LOCATION Provide Clearances ......................................................... 7-8 Provide Air Openings to Room ..................
Installation & Operation Manual Please read before proceeding ⚠WARNING Installer – Read all instructions, including this manual and the Armor Wall Mount Water Heater Service Manual, before installing. Perform steps in the order given. Have this water heater serviced/inspected by a qualified service technician, at least annually. Failure to comply with the above could result in severe personal injury, death or substantial property damage.
Installation & Operation Manual The Armor Wall Mount Water Heater - How it works... 1. Stainless steel heat exchanger Allows water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process. 2. Combustion chamber access cover Allows access to the combustion side of the heat exchanger coils. 3. Blower The blower pulls in air and gas through the venturi (item 5).
Installation & Operation Manual The Armor Wall Mount Water Heater - How it works...
Installation & Operation Manual Ratings HLW * Model Number Note: Change “N” to “L” for L.P. gas models. CSA Input Modulation Btu/hr Water Content Gallons Water Connections Gas Connections (Note 2, 3) Vent/Air Size (Note 1) WAN125PM 25,000 - 125,000 1.0 1" 1/2" 3"/3" WAN200PM 39,800 - 199,000 1.8 1-1/4" 1/2" 3"/3" *Note: Applies to WAN200 Models ONLY. NOTICE Maximum allowed working pressure is located on the rating plate. Notes: 1.
Installation & Operation Manual 1 Determine water heater location Installation must comply with: • Local, state, provincial, and national codes, laws, regulations, and ordinances. • National Fuel Gas Code, ANSI Z223.1 – latest edition. • National Electrical Code. • For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.
Installation & Operation Manual 1 Determine water heater location Figure 1-1 Closet Installation - Minimum Required Clearances TOP 6" MINIMUM For closet installations, CPVC or ⚠WARNING stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to VENTILATING* AIR OPENING follow this warning could result in fire, personal injury, or death.
Installation & Operation Manual 1 Determine water heater location (continued) Provide air openings to room: Residential garage installation Armor wall mount water heater alone in equipment room Precautions 1. No air ventilation openings into the equipment room are needed when clearances around the Armor wall mount water heater are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1.
Installation & Operation Manual 1 Determine water heater location Table 1A Corrosive Contaminants and Sources Products to avoid: Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, de
Installation & Operation Manual 1 Determine water heater location (continued) When removing a water heater from existing common vent system: ⚠ DANGER Do not install the Armor wall mount water heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.
Installation & Operation Manual 2 Prepare water heater Remove water heater from wood pallet 1. After removing the outer shipping carton from the water heater, remove the parts box. 2. To remove the water heater from the pallet: a. Remove the two (2) lag bolts securing the bottom of the unit to the pallet. b. Lift the water heater off the wall bracket mounted to the pallet. 3. Remove the two (2) lag bolts securing the wall bracket to the wood pallet.
Installation & Operation Manual 2 Prepare water heater (continued) 12. Reattach the wiring connector to the gas valve. Tighten the screw on the wiring connector to secure to the gas valve. 13. Turn the gas valve power switch to the “ON” position. 14. Reattach the bezel to the unit. Reconnect the ribbon cable to the control board. 15. After installation is complete, fill out the gas conversion label (in the conversion kit bag) and affix it to the unit under the water heater rating plate inside the unit.
Installation & Operation Manual 3 General venting Direct venting options - Sidewall Vent Figure 3-1 Two-Pipe Sidewall Termination - See page 21 for more details Figure 3-2 PVC/CPVC Concentric Sidewall Termination - See page 28 for more details Direct venting options - Vertical Vent Figure 3-3 Two-Pipe Vertical Termination - See page 31 for more details 14 Figure 3-4 PVC/CPVC Concentric Vertical Termination - See page 33 for more details Figure 3-5 Vertical Vent, Sidewall Air
Installation & Operation Manual 3 General venting (continued) Install vent and combustion air piping ⚠ DANGER ⚠WARNING The Armor wall mount water heater must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.
Installation & Operation Manual 3 General venting Requirements for installation in Canada 1. Installations must be made with a vent pipe system certified to ULC-S636. IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636. 2. The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection. 3.
Installation & Operation Manual 3 General venting (continued) Air contamination Supports Vent system must be supported horizontally to prevent sagging. Methods and intervals for support vary by vent manufacturer and vent material. Vent support methods and intervals shall adhere to vent manufacturer's instructions, where applicable. Vent, air piping and termination: The Armor wall mount water heater vent and air piping can be installed through the roof or through a sidewall.
Installation & Operation Manual 3 General venting PVC/CPVC This product has been approved for use with the PVC/CPVC vent materials listed in Table 3B. 1. 2. Installing vent and air piping ⚠WARNING The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance if PVC/CPVC vent is to be used. The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe.
Installation & Operation Manual 3 General venting (continued) Polypropylene NOTICE The installer must use a specific vent starter adapter at the flue collar connection. This adapter is supplied by the vent manufacturer to adapt to its vent system. See Table 3D for approved vent adapters. NOTICE All vent connections MUST be secured by the vent manufacturer's joint connector (FIG. 3-9). This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3C.
Installation & Operation Manual 3 General venting Stainless steel vent NOTICE This product has been approved for use with stainless steel using the manufacturers listed in Table 3E. ⚠WARNING Use only the materials, vent systems, and terminations listed in Tables 3E and 3F. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall ⚠WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage. A gas vent extending through an exterior ⚠WARNING wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall Figure 4-1C Alternate PVC/CPVC/SS Vent Termination - Typical Stainless Steel Sidewall Termination of Air and Vent w/Field Supplied Fittings BIRD SCREEN TO WATER HEATER INTAKE AIR CONNECTION 12" (305 MM) MIN 15" (381 MM) MAX FROM WATER HEATER VENT PIPE CONNECTION 12" (305 MM) MIN 5. Maintain clearances as shown in FIG.’s 4-1A thru 4-4B, pages 21 thru 25. Also maintain the following: a.
Installation & Operation Manual 4 Sidewall direct venting (continued) Figure 4-4A Direct Vent Terminal Clearances Table 4B Direct Vent Terminal Clearances Canadian Installations¹ US Installations² Clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) B= Clearance to window or door that may be opened 6 in (15 cm) for appliances < 10,000 Btuh (3 kW), 12 in (30 cm) for appliances > 10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW), 36 in (91 cm) for appliances > 100,000 B
Installation & Operation Manual 4 Sidewall direct venting Table 4B Direct Vent Terminal Clearances (continued) J= Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in (15 cm) for appliances < 10,000 Btuh (3kW), 12 in (30 cm) for appliances > 10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW), 36 in (91 cm) for appliances > 100,000 Btuh (30 kW) 6 in (15 cm) for appliances < 10,000 Btuh (3kW), 9 in (23 cm) for appliances > 10,000 Btuh (3 kW) and < 5
Installation & Operation Manual 4 Sidewall direct venting (continued) Table 4C Other than Direct Vent Terminal Clearances * † ‡ Canadian Installations¹ US Installations² A= Clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) B= Clearance to window or door that may be opened 6 in (15 cm) for appliances < 10,000 Btuh (3 kW), 12 in (30 cm) for appliances > 10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW), 36 in (91 cm) for appliances > 100,000 Btuh (30 kW) 4 ft (1.
Installation & Operation Manual 4 Sidewall direct venting Prepare wall penetrations 1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. Vent pipe penetration: a. Cut a hole for the vent pipe.
Installation & Operation Manual 4 Sidewall direct venting (continued) Figure 4-5B Polypropylene Sidewall Termination Assembly Multiple vent/air terminations 1. When terminating multiple Armor wall mount water SIDEWALL ADAPTER heaters terminate each vent/air connection as described in (AIR) WALL this manual (FIG. 4-6A).
Installation & Operation Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit (100140480). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-7. The required combustion vent pipe materials are listed in Table 3B, on page 18 of this manual. 4.
Installation & Operation Manual 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent Figure 4-9 Concentric Vent Dimensional Drawing 6. Install the Y concentric fitting and pipe assembly through the structure’s hole. NOTICE Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole. 7. Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly.
Installation & Operation Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent Figure 4-11 Concentric Vent Sidewall Attachment CAUTION DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation. 9. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-11 for proper pipe attachment. 10.
Installation & Operation Manual 5 Vertical direct venting Vent/air termination – vertical ⚠WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent Determine location Locate the vent/air terminations using the following guidelines: 1.
Installation & Operation Manual 5 Vertical direct venting Vent/air termination – vertical Prepare roof penetrations 1. 2. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: • 4½ inch hole for 3 inch vent pipe b.
Installation & Operation Manual 5 Vertical direct venting (continued) Vertical termination – optional concentric vent Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4. 2. Cut one (1) hole (5 inch diameter) into the structure to install the termination kit. 3.
Installation & Operation Manual 5 Vertical direct venting Vertical termination – optional concentric vent ⚠WARNING Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death. 6. 7.
Installation & Operation Manual 5 Vertical direct venting (continued) Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing. Figure 5-8 Concentric Vent Example 1 FLUE EXHAUST Concentric Venting Arrangement The venting is to be vertical through the roof. The annular space between the O.D.
Installation & Operation Manual 5 Vertical direct venting Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual. Figure 5-10 Existing Vent as a Chase AIR INLET FLUE EXHAUST SEAL CAP EXISTING SEAL FLUE OUTLET *For concept illustration only. Individual installations may vary due to job site specific equipment.
Installation & Operation Manual 6 System piping System water piping methods Observe a minimum of 1/4 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials. General piping information Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-4 thru 6-8), which will guide you through the installation of the Armor wall mount water heater. 1.
Installation & Operation Manual 6 System piping Scalding Piping components This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury.
Installation & Operation Manual 6 System piping (continued) Figure 6-4 Single Heater - Single Tank BUILDING RETURN FLOW CHECK VALVE (TYPICAL) COLD WATER SUPPLY BUILDING RECIRCULATION FILTER (IF REQUIRED SEE START-UP SECTION) MIXING VALVE EXPANSION TANK THERMOMETER WATER HEATER HOT WATER SUPPLY UNION (TYPICAL) BALL VALVE (TYPICAL) TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) WATER HEATER CIRCULATOR STORAGE TANK FLOW SWITCH Y-STRAINER DIR #2000570320_000 DRAIN ⚠ CAUTION The piping will not
Installation & Operation Manual 6 System piping Figure 6-5 Single Heater - Single Tank (2 Temperature) 180° HOT WATER SUPPLY BALL VALVE (TYPICAL) FLOW CHECK VALVE (TYPICAL) WATER HEATER TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) 140° HOT WATER SUPPLY HIGH TEMPERATURE BUILDING RETURN THERMOMETER LOW TEMPERATURE BUILDING RETURN MIXING VALVE UNION (TYPICAL) WATER HEATER CIRCULATOR BUILDING RECIRCULATION FILTER (IF REQUIRED SEE START-UP SECTION) FLOW SWITCH COLD WATER SUPPLY EXPANSION TANK
Installation & Operation Manual 6 System piping (continued) Figure 6-6 Single Heater - Double Tank BUILDING RETURN FLOW CHECK VALVE (TYPICAL) BALL VALVE (TYPICAL) COLD WATER SUPPLY THERMOMETER MIXING VALVE BUILDING RECIRCULATION FILTER (IF REQUIRED SEE START-UP SECTION) EXPANSION TANK WATER HEATER HOT WATER SUPPLY UNION (TYPICAL) FLOW SWITCH TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) BALL VALVE (TYPICAL) WATER HEATER CIRCULATOR Y-STRAINER DIR #2000570323_000 STORAGE TANK (TYPICAL) DRAIN
Installation & Operation Manual 6 System piping Figure 6-7 Double Heater - Single Tank Model 151 200 2 Number of Units 4 5 6 3 7 8 Required Pipe Sizes in NPT with Standard Pump 1 1/2" 2" 2" 2" 2 1/2" 3" 3" 2" 2" 2 1/2" 2 1/2" 3" 3" 3" EXPANSION TANK FLOW CHECK VALVE (TYPICAL) Model 151 200 2 3 Number of Units 4 5 6 7 8 Required Pipe Sizes in NPT with Upsized Pump 1 1/2" 2" 2 1/2" 2 1/2" 3" 3" 3" 2" 2 1/2" 3" 3" 4" 4" 4" WATER HEATER (TYPICAL) COLD WATER SUPPLY BUILDING RECIRCULATION FIL
Installation & Operation Manual 6 System piping (continued) Figure 6-8 Double Heater - Double Tank Model 151 200 2 3 Number of Units 4 5 6 7 8 Required Pipe Sizes in NPT with Standard Pump 1 1/2" 2" 2" 2" 2 1/2" 3" 3" 2" 2" 2 1/2" 2 1/2" 3" 3" 3" EXPANSION TANK FLOW CHECK VALVE (TYPICAL) Model 151 200 2 3 Number of Units 4 5 6 7 8 Required Pipe Sizes in NPT with Upsized Pump 1 1/2" 2" 2 1/2" 2 1/2" 3" 3" 3" 2" 2 1/2" 3" 3" 4" 4" 4" WATER HEATER (TYPICAL) COLD WATER SUPPLY BUILDING RECIR
Installation & Operation Manual 7 Gas connections Connecting gas supply piping 1. Remove the front access panel and refer to FIG. 7-1 to pipe gas to the water heater. a. Install a field supplied sediment trap / drip leg upstream of the water heater gas controls. 2. Support piping with hangers, not by the water heater or its accessories. ⚠WARNING Figure 7-1 Gas Supply Piping The gas valve and blower will not support the weight of the piping.
Installation & Operation Manual 7 Gas connections ⚠WARNING ⚠WARNING ⚠WARNING (continued) Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. Armor wall mount water heaters are typically shipped ready to fire on natural gas. Check the water heater rating plate to determine which fuel the water heater is set for. If set to natural gas, it may be converted to LP by installing an orifice (see pages 12 thru 13).
Installation & Operation Manual 7 Gas connections Table 7A Natural Gas Pipe Size Chart Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c.
Installation & Operation Manual 7 Gas connections (continued) 13. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics. Figure 7-3 Inlet Gas Supply Check Gas valve replacement The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances.
Installation & Operation Manual 8 Field wiring ⚠WARNING NOTICE ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. If original wiring as supplied with the water heater must be replaced, use only type 105°C wire or equivalent.
Installation & Operation Manual 8 Field wiring (continued) Tank thermostat Flow switch 1. Connect the tank thermostats (isolated contact only) to the tank thermostat contacts as shown in FIG. 8-3. 1. A flow switch is used to guarantee flow through the water heater before allowing it to fire. The flow switch must be installed at the water heater outlet. Tank sensor 1. By installing a tank sensor, the SMART SYSTEM control can perform the tank thermostat function.
Installation & Operation Manual 8 Field wiring Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the water heater is responding to a call for heat. Alarm contacts The SMART SYSTEM control closes another set of contacts whenever the water heater is locked out or the power is turned off.
NO COM LOW WATER CUTOFF TANK THERMOSTAT FLOW SWITCH BUILDING MANAGEMENT SYSTEM A B SHIELD TANK SENSOR Field wiring LOUVER PROVING SWITCH SHIELD B TO A NEXT HEATER 8 24VAC LOUVER RELAY COIL FROM B PREVIOUS A HEATER Installation & Operation Manual (continued) Figure 8-3 Low Voltage Field Wiring Connections 51
Installation & Operation Manual 9 Condensate disposal Condensate drain NOTICE Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with ASME D2564 or F493. For Canada use CSA or ULC certified PVC or CPVC pipe, fittings, and cement. NOTICE To allow for proper drainage on large horizontal runs, a second line vent may be required and tubing size may need to increase to 1 inch.
Installation & Operation Manual 10 Start-up Check/control water chemistry Check for gas leaks Conduct water quality testing prior to installing the appliance. Various solutions are available to adjust water quality. See the following table for properly operating the water heater with the appropriate water chemistry. Good water quality will help extend the life of the appliance by reducing the effects of scale build-up and corrosion.
Installation & Operation Manual 10 Start-up Figure 10-1 Condensate Trap Check system and water heater Check water piping 1. Check system piping for leaks. If found, shut down the water heater and repair immediately. (See WARNINGS on pages 53 and 54 (startup) regarding failure to repair leaks.) 2. Check Delta T. Reference Section 6 - System Piping on page 38 for more information regarding Delta T. 3. Vent any remaining air from the system using manual vents.
Installation & Operation Manual 10 Start-up (continued) Figure 10-2 Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas.
Installation & Operation Manual 10 Start-up Check flame and combustion (continued) Set water heater operation 2. Place the water heater into the active position by pressing the RIGHT SELECT [ON] key (FIG. 11-1, page 62). Set tank set point temperature 3. Locate the pinhole button below the RESET button on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the water heater into Service Mode.
Installation & Operation Manual 10 Start-up (continued) Configuration of the cascade Set clock NOTICE Please note that the brackets ([]) denote screen status. The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the water heater is installed, and anytime the water heater has been powered off for more than 4 hours. Use the following procedure to set the clock: 1.
Installation & Operation Manual 11 Operating information General Protection features How the water heater operates Outlet temperature, flue temperature, and temperature rise limiting The Armor wall mount water heater uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the water heater through the heat exchanger and flue piping.
Installation & Operation Manual 11 Operating information Monitor external limits Connections are provided on the connection board for external limits such as flow switch, gas pressure switches, and a louver proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open. Runtime and alarm outputs The water heater provides dry contacts for indicating when the water heater is running, and when it is unable to operate.
Installation & Operation Manual 11 Operating information Cascade Access modes When multiple water heaters are installed, they can be wired together in a cascade sequence. A maximum of eight water heaters can be controlled from a single control. In this application one water heater would be designated as the Leader control and all others would be designated as Member controls. The Leader control can be programmed to use Lead/Lag or Efficiency Optimization control methods.
Installation & Operation Manual 11 Operating information (continued) Sequence of operation OPERATION DISPLAY 1. The control will turn on the water heater pump (always ON except in Night Setback). The flow switch and/or LWCO must close. 2. The control turns on power to the louver relay. The louver proving switch, air pressure switch, and blocked drain switch must close. 3. The control starts the prepurge cycle. 4.
Installation & Operation Manual 11 Operating information Armor wall mount water heater control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor water heater operation.
Installation & Operation Manual 11 Operating information (continued) Figure 11-2 Status Display Screen Status Display Screens Section Display Description STANDBY The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat. START A (Water heater Status Bar) The unit has begun a burn cycle and is checking all safety circuits. PREPURGE The unit has initiated a prepurge period on a call for heat.
Installation & Operation Manual 11 Operating information Status Display Screens (cont’d) Section Display TANK: The temperature read by the tank sensor (if connected). INLET TEMP: The temperature read at the inlet to the heat exchanger. OUTLET TEMP: The temperature read at the outlet of the heat exchanger.
Installation & Operation Manual 11 Operating information Section (continued) Status Display Screens (cont’d) Display Description Turning the NAVIGATION dial will select the next or previous Status Screen. Pressing the NAVIGATION dial will show the next fault, NSB (Night Setback) trigger, or ramp delay setting. Pressing the NAVIGATION dial will select the setting indicated by the cursor. E (NAVIGATION Dial Function) Pressing the NAVIGATION dial will display the Set Points Screen.
Installation & Operation Manual 12 Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician (see the following pages for instructions) Owner maintenance General: • Address reported problems • Inspect interior; clean and vacuum if necessary; Daily • Check water heater area • Clean condensate trap and fill with fresh water ANNUAL START-UP • Check for leaks (water, gas, flue, condensate) • Check vent piping • Verify flue and air lines in good condit
Installation & Operation Manual 12 Maintenance ⚠WARNING ⚠WARNING ⚠WARNING (continued) Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
Installation & Operation Manual 12 Maintenance ⚠WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death. Check water system 1. Verify all system components are correctly installed and operational. 2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 PSI). 3. Watch the system pressure as the water heater heats up (during testing) to ensure pressure does not rise too high.
Installation & Operation Manual 12 Maintenance (continued) Perform start-up and checks Check flame signal 1. Start water heater and perform checks and tests specified in Section 10 - Start-up. 1. At high fire the flame signal shown on the display should be at least 10 microamps. 2. Verify cold fill pressure is correct and that operating pressure does not go too high. 2. A lower flame signal may indicate a fouled or damaged flame sense electrode.
Installation & Operation Manual 12 Maintenance ⚠WARNING The water heater contains ceramic fiber materials. Use care when handling these materials per instructions in the Service Manual. Failure to comply could result in severe personal injury. 5. Remove the condensate hose from the heat exchanger end. Connect a field supplied 3/4" diameter hose to a drain pan. Using field supplied means, cover the refractory in the back of the combustion chamber of the heat exchanger.
Installation & Operation Manual 13 Diagrams Figure 13-1 Ladder Diagram JUNCTION BOX 120VAC NEUTRAL GROUND TERMINAL STRIP 120V SUPPLY "L" TERMINAL STRIP 120V SUPPLY "N" L IN L OUT AW MODELS ONLY INTEGRATED CONTROL ON / OFF SWITCH X1-1 F2 1 2 BLOWER 3.15A X1-6 3 F1 BUILDING RECIRC PUMP CONTACTS X1-2 BUILDING RECIRC PUMP RELAY 5A BUILDING RECIRC PUMP RELAY BUILDING RECIRC PUMP X1-3 DHW PUMP DHW PUMP RELAY DHW PUMP RELAY F3 DHW PUMP CONTACTS .
Installation & Operation Manual 13 Diagrams Figure 13-2 Wiring Diagram LOW VOLTAGE 120 VAC HIGH VOLTAGE BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONTROL CONNECTION BOARD JUNCTION BOX BELL JUMPER SILENCING SWITCH ALARM BELL COM ALARM CONTACTS RUN-TIME CONTACTS 24 VAC LOUVER RELAY COIL LOUVER PROVING SWITCH GAS PRESSURE SWITCH FLOW SWITCH TANK THERMOSTAT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X-7 X1-3 OR/BK L N OR DHW PUMP OR NO X1-4 CN5-1 CN5-8 CN5-2 CN5
Notes 73
Notes 74
Notes 75
Revision Notes: Revision A (ECO #C11832) initial release. Revision B (ECO #C11814) reflects updates made to the polypropylene de-rate amounts (R06316). Revision C (ECO #C14411) reflects the removal of the page number reference on page 14, the addition of the corrosive contaminant warning on pages 3 and 7 (R06313), changes made to Table 7A - Gas Piping Chart on page 43 (R6621), along with updating the flex piping information (R06464) on page 19. Revision D (ECO #C14713) reflects high altitude updates.
